Lead Engineer Industrial Automation

The Lead Engineer - Industrial Automation will design, commission, and scale fully automated production solutions for ETO electrical assemblies (switchboards, LV assemblies), covering robotics, PLC/motion controls, vision/AI-guided assembly, digital work instructions, and MES/IIoT integration. "* System Architecture & Commissioning Ownership: Convert URS/SRS to detailed control architecture (cells/lines, safety zoning, networks); author FMEA/PFMEA; define ISA‑S88 state machines; lead design reviews, pre‑FAT, FAT, SAT, ramp‑up, handover. Robotics Integration (ETO Assembly & Wiring): Flexible robotic cells for panel/enclosure handling, device insertion, torqueing, label OCR, busbar handling, wire strip/crimp, harness routing, riveting, and EOL tests; EOAT/fixtures with compliant tooling and quick‑change. Working experience with Robot Programming & OLP/Simulation: Native stacks (URScript, TP/KAREL, RAPID, KRL, INFORM, ACE, AS, VAL3, SPEL+, MELFA BASIC, FD, ORiN); OLP (RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate); reach/collision/cycle‑time validation and post‑processors. Working experience with PLC/Motion/HMI/SCADA: Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi; IEC‑61131‑3 logic; motion/VFD; safety PLCs; HMI/SCADA; S88 state modeling. Networks/Fieldbus & IIoT: EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls. Collaborate to work with expert peers inVision & In‑Station AI to commission: Keyence/Cognex/IDS/SICK/RealSense; OCR/label verification, bin‑picking, hole/slot location, projector guidance; OpenCV/Cognex Designer pipelines. Working experience with Digital Work Instructions (DWI) & AR based deployment: LightGuide, Arkite, PTC Vuforia; operator guidance, serialization, step traceability, rework routing. MES/IIoT/Data Backbone: Apriso/Ortems/eMaint integration; WO/routing/serial/QA mapping; FPY/OEE/SPC dashboards via MQTT/Kafka/OPC‑UA. Safety & Compliance: ISO 12100, ISO 10218/TS 15066, ANSI/RIA R15.06, IEC 61508/62061, ISO 13849‑1; risk assessments; LOTO; CE/UL doc packs. Industry 4.0 Lab Ownership: Lab architecture, vendor ecosystem, standard cell templates, commissioning checklists, code libraries, PoCs, training. Supplier/Vendor & Project Governance: RFQs/specs, ATPs, spares, integrator/OEM management, coding standards, change control, KPI impact." Risk assessment (PL/SIL), guarding/sensors, LOTO; CE/UL doc sets; factory safety audits. Quality/EOL Automation Automated electrical functional tests, device actuation, SPC; barcode/RFID; dashboards. Networking ability across organization to understand critical business problems Clear and effective verbal and written communication with stakeholders Strong problem-solving skills for complex automation challenges (DMAIC Certified is preferred) Skilled in planning, budgeting, and executing projects on time. Established project management skills while handling multiple projects Comfortable working in dynamic environments with evolving technologies Ability to document, plan, market, and execute programs Vendor negotiation B.E./B.Tech or M.E./M.Tech in Electrical/Electronics/Mechatronics/Robotics/Industrial Engineering. 8+ years commissioning HMLV/ETO automation (concept→design→build→FAT/SAT→ramp) with multi‑robot and multi‑PLC environments. Universal Robots (UR), FANUC, ABB, KUKA, Yaskawa Motoman, Omron/TM, Kawasaki, Stäubli, Epson, Mitsubishi, Nachi, Denso. Languages: URScript/PolyScope; TP/KAREL; RAPID; KRL; INFORM; ACE; AS; VAL3; SPEL+; MELFA BASIC; FD; ORiN. Capabilities: TCP/tool/user frames; external axes; force/torque; vision guidance; safe zones; multi‑robot cell balancing; program versioning. OLP & Simulation RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate—reach/collision, cycle‑time, buffer sizing, EOAT feasibility, layout/MTM/MOST, post‑processors. PLC/Motion/HMI/SCADA Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi—IEC‑61131‑3 (ST/LD/FBD/SFC), motion/VFD/servo tuning, safety PLCs, HMI/SCADA, historians, alarm/event models, S88 state machines. Networks/Fieldbus & IIoT EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; safety over bus (CIP Safety/Profisafe); OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls. Vision & Metrology Keyence/Cognex/IDS/SICK; barcode/OCR, dimensional checks, bin‑picking, projector alignment; camera/lens/light selection; calibration tooling; accuracy validation. EOAT/Fixtures & Pneumatics/Electrical Pneumatic/electric grippers; compliant tooling; quick‑change; wire strip/crimp heads; screwdrivers/torque tools; panel build standards, EMC/grounding; compressed air design (FRL, flow/pressure), vacuum. DWI/AR & Traceability LightGuide/Arkite/Vuforia; operator guidance; step enforcement; serialization; label compliance; rework routing. MES/ERP/PLM Integration Apriso/Ortems/eMaint + ERP/PLM; object mapping (WO/routing/serial/QA); FPY/OEE and SPC integration; data lineage and audit. Structured text for PLC, Python for data/vision, Git for version control; CSV/JSON schema for recipes; secure design (IEC 62443 basics)Deep knowledge in electrical and instrumentation design Ability to perform system validation and FAT/SAT testing "* Self-motivated; Passionate to bring own ideas to applications